PSG COLLEGE OF TECHNOLOGY

DEPARTMENT OF MECHANICAL ENGINEERING

19M612 – INNOVATION PRACTICES LABORATORY

DESIGN AND DEVELOPMENT OF GENERATIVE SUSPENSION

TEAM MEMBERS: UNDER THE GUIDANCE OF:

21M104 – Bawan Siddharth
21M120 – Jeisurya Dr. Syath Abuthakeer S
22M405 – Srinivasan
 Methods and ideas

1. Generative suspension with rack-pinion mechanism

The rack-pinion is attached to the suspension system which rotates the
gears and in turn the generator to produce current.

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 Rack-pinion mechanism
 The up and down motion of the suspension in turn moves the rack.
 The rack transfers the linear motion into rotatory motion by a pinion.
 The one way clutch is used to transmit the up and down motion seperately to
bevel gears.
 The bevel gear motion is then magnified via a planetary gear set then to the dc
motor.

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 2.Generative suspension with electromagnetic
induction
• A magnetic core with copper windings is used and this is attached to the
suspension.

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 LITERATURE REVIEW
[1] Hydrostatic energy-storage type
The working principle is to convert the vibration energy consumed by the suspension
system into hydraulic energy, which is stored for the use of hydraulic energy-
consuming components on the suspension system.

[2] Electromagnetic coil type

The working principle is to replace the traditional shock absorber with an
electromagnetic coil device. It can convert the vibration energy dissipated by the
system into electrical energy and store it in the battery.

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Figure: (a) Diagram of the linear electromagnetic shock absorber and (b) the cross section of the magnet assembly
[3] Ball screw type
The working principle of ball screw shock absorber is to replace the traditional shock
absorber with a ball screw mechanism. When the shock absorber reciprocates with
the road bump, the ball nut moves up and down, driving the screw and the electric
motor in order to generate electricity for reuses.

4] Rack-pinion type
The working principle is to replace the shock absorber with a motor and a rack-
pinion mechanism. The mechanism maintains engagement under the action of
spring compression and transfers vibration energy to the generator for electrical
energy.

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Performance comparison of shock absorbers

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Matlab code

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Results obtained
For Rack and pinion type For electromagnetic coil type

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Objectives

1. To generate the reciprocating motion as a prime input.

2. To convert reciprocating motion into rotary motion by rack and pinion.
3. To magnify the rotary motion using chain drive.
4. To store the kinetic energy using flywheel.
5. To transfer the energy to dynamo and to generate electricity.
6. To light up the indicator lamps attached to system as final output.
7. To conserve the vibrational energy which is being dissipated as heat.

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Design calculation - Nomenclature
• m = mass of the flywheel k = radius of gyration
• I = Mass moment of inertia Pd=Diameter pitch m=Module
• A = Addendum
• B = Deddendum
• Pc = Circular Pitch
• ρ = Density of concrete
• K1= Load factor K2= Factor for distance regulation K3=Factor for center
distance of sprocket
• K4=Factor for position of sprocket K5=Lubrication factor K6=Rating factor
• T1 = Tension in tight side T2 = Tension in slack side
• Dact =Actual diameter of shaft
• Tmax= Maximum torque on shaft 11
Design calculation - Calculation
Let the force put by human hand on rack = 30 kg.[9]
30x10 =300 N
In one minute rack will go up & down 30 times . Now pinion has 24 number of
teeth so in 1 minute pinion Rpm will be 15 because only 12 teeth will come in
contact at a time only with rack.
Now, Gear-1, teeth = 44 and Rpm = 15
Gear-2, teeth = 18
Gear teeth ratio = 18:44 =1:2.4
Speed of gear-2 = 2.4x15 = 36 Rpm
Rpm of flywheel is 85 Rpm.
Diameter of flywheel = 350mm = 0.350 m
Width of flywheel = 80mm =0.080 m
.‘. Volume of flywheel = π x r 2 x b = 0.007696 m 3 12
Design calculation - Calculation

Flywheel is filled with concrete inside. ρ = 2400 kg/m3 .

.’. Mass of flywheel = 0.007696 x 2400 = 18.47 kg
The mean kinetic energy of the flywheel, E =1/2 .I .ω2 =1/2m.k2 .ω2
= 0.6293 N-mm
Velocity ratio = 50 : 350 = 1 : 7
Speed of dynamo pulley = 85 x 7 = 595 Rpm. Purchase 500 Rpm standard
dynamo from the market, which produce 10 watts power at full speed.
Torque transmitted by shaft, T = π/16 x τ x d 3
Select permissible shear stress (τ) from design data book τ = 70 N/mm2
Thus, 9750 = π /16 x d 3 x 70 d=8.91mm

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Design calculation - Calculation

Taking factor of safety = 1.8

Dact = 8.9 x 1.8 = 16 mm
Select diameter of shaft = 20 mm.
For 20mm shaft diameter take standard bearing. Spherical ball or deep groove
ball bearing = 20mm
Spur gear terminology, Take the gear of teeth, T = 24 D = 65mm b= 25mm.
Calculate spur gear terminology and check whether it can bear load.
Pd = T/D = 24/65 = 0.37 mm. m = D/T = 65/24 = 2.70mm.
Pc = πD/T = π x 65/24 = 8.50 mm.
A = 1/Pd= 1/0.37 = 2.70mm. B = 1.157/Pd = 1.157/0.37 = 3.13 mm.
Root diameter = T-2/Pd = 22/0.37 = 59.45 mm.
Base circle = D x Cos(Pd x A) = 65 x cos(0.37x2.70) = 64.99 mm 14
Design calculation - Calculation

Pc = 3.1416/Pd = 8.49mm.
Thickness = 3.1416D/2N = 1.57/Pd = 4.24mm.
By using the Lewis equation find the maximum load tooth can bear.
Lewis equation Wt = ςw x b x Pc x y
The permissible working stress (ςw ) in Lewis equation depends upon the gear
material and may be obtained by Barth formulae.
ςw = ςo x Cv ςo is allowable static stress at elastic limit of the material.
From design data book
ςo = 455mpa Cv = 4.5/4.5+v = 4.5/4.5+ 3.40 = 0.57
V = πDN/60 = π x 0.065 x 1000/60 = 3.40 m/s
ςw = ςo x Cv ςw = 455 x 0.57 = 259.35
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Design calculation - Calculation

Y is known as Lewis form factor or tooth form factor.

Y = 0.154 – 0.912/T --------------- ( for 20 degree full depth involute system.)
Y = 0.154 – 0.912/24 = 0.116.
Wt = ςw x b x Pc x y
Wt = 259.35 x 25 x 8.49 x 0.116
= 6385 N =651 kg.
Putting 30 kg load on gear so design of our gear is safe.

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Design calculation – Design of chain and
sprocket
Transmission Ratio = Z2 / Z1 = 44/18 = 2.44
Select number of teeth on pinion sprocket as 18 teeth.
Z1 = 18 teeth
Design calculation – Selection of pitch of
sprocket
The pitch is decided on the basis of Rpm of sprocket.
Rpm of pinion sprocket is variable in normal condition it is = 36 rpm
For this Rpm value select pitch of sprocket as 15mm from table.
P = 15mm

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Design calculation - .Calculation of minimum
center distance between sprockets
Transmission ratio= Z2 / Z1 = 44/18 = 2.44 which is less than 5
Minimum center distance = C + (80 to 150 mm) Where C = (Dc1 + Dc2)/2
C = 120 mm
Minimum center distance = 120 + (80 to 150 mm ) = 280 mm
Design calculation – Calculation of values of
constants
K1 = 1.25
K2 = 1.25
K3 =0.8
K4 = 1
K5 = 1.5
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K6 = 1.0
Design calculation - Calculation of value of factor
of safety
For pitch = 15 & speed of rotation of small sprocket = 36 rpm
Factor of safety = 8.55
Calculation of value of allowable bearing stress :
For pitch = 15 and speed of rotation of small sprocket = 36 rpm
Allowable bearing stress = 2.87 kg / cm2 = 2.87 × 981 / 100 =28 N /mm2
For horizontal position coefficient of sag
K = 6 T1/T2 = e 
T1/T2 = e 0.35 x 2.971
T1 = 2.80T2
T = ( T1 – T2 ) X R 9750 = ( 2.80 T2 – T2 ) X 85

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Design calculation - Calculation of value
of factor of safety
T2 = 63.72 N
T1 = 2.80 X 63.72 T1 = 178.43 N
So tension in tight side = 178.43 N Stress = force / area
Stress induced = 861/ ( 3.14 × 4 2 ) = 17.22 N /mm2
As induced stress is less than allowable stress = 28 N /mm2
Design of sprocket is safe.
Tmax=9750N-mm

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• Journals referred
– https://www.technicaljournalsonline.com/ijeat/VOL%20III/
IJAET%20VOL%20III%20ISSUE%20II%20APRIL%20JUNE
%202012/13%20IJAET%20Vol%20III%20Issue%20II
%202012.pdf

– https://reader.elsevier.com/reader/sd/pii/S266612331930008
X?token=FDACBFB1475D2D84F47CDC614CFEB24061BE
8953038DD43D49FD2EB34F6C02F46037EB6571B3958C0
DB8D93FFA670579&originRegion=eu-west-1&originCreatio
n=20230102134512

– https://ieeexplore.ieee.org/document/6974304
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